Modularized construction and prefabrication assembly method for roller compacted concrete

Abstract

The invention discloses a roller compacted concrete modular construction and prefabrication method, and belongs to the technical field of modular construction of overflow surfaces. The reserved surface of the dam is scabbled and washed, and the binding power of new and old concrete is enhanced; accurately marking an overflow surface curve by using a total station; a formwork is installed after the formwork dragging track is welded; after pouring, concrete is vibrated to ensure compactness; the formwork is in sliding connection with the track through the sliding groove, and concrete is prevented from extruding the formwork out of the track during pouring; modularized design is adopted in the formwork, all module units are rotationally connected through independent connecting pieces, and sliding blocks are integrally formed on the outer sides and are in sliding connection with sliding grooves of the formwork dragging rails. During installation, the assembled module is directly installed on a formwork dragging track, the formwork can adapt to changes of the curvature of an overflow face, in construction, after concrete of a current pouring layer is initially set, a traction mechanism can directly drag the formwork to move upwards along the track to conduct pouring of the next layer, the formwork with the corresponding curvature does not need to be replaced, the formwork installation time is shortened, and the construction efficiency is improved. And the problem of long assembly time is effectively solved.

Description

Technical Field

[0001] The invention belongs to the technical field of modular construction of overflow surfaces, and particularly relates to a method for roller compacted concrete modular construction and prefabricated assembly. Background Technique

[0002] The overflow surface needs to meet multiple functions such as flood discharge, energy dissipation, and anti-scouring. Its shape and curvature directly affect the flow pattern of water and the energy dissipation effect; complex curved surface design can better adapt to different hydraulic conditions and improve the safety and economy of the project; the construction of the existing overflow surface mostly adopts the slip form pouring technology, but the existing single formwork is difficult to adapt to complex overflow curved surfaces, that is, the curvature of the overflow curved surface is inconsistent. Therefore, the complex curved surface is divided into multiple small segments, and each small segment uses a separate formwork unit. These formwork units can be adjusted and spliced according to the shape of the local curved surface, so as to adapt to the entire complex curved surface. However, the segmented formwork needs to be assembled and adjusted on site. The assembly process is complex and time-consuming. The installation and positioning of each formwork unit require precise operation, increasing the construction difficulty and time cost. The manufacture of the segmented formwork needs to be customized according to the curved surface shape of each small segment, with complex manufacturing processes and high costs. In addition, the reuse rate of the formwork is relatively low, further increasing the construction cost.

[0003] In summary, this kind of segmented formwork has the problems of long assembly time and high cost of segmented formwork manufacturing. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for roller compacted concrete modular construction and prefabricated assembly in view of the above deficiencies in the prior art. The design is novel and reasonable, the construction efficiency is high, the practicability is strong, and it is convenient to popularize and use.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is: A method for roller compacted concrete modular construction and prefabricated assembly, comprising the following steps: S1. Construction preparation; pour the main body of the dam with roller compacted concrete, roughen and wash the reserved surface on the main body of the dam, use a total station to set the line on the side of the pier, and mark the overflow surface curve on both piers; tie steel bars on the reserved surface of the dam; S2. Formwork installation; drive cramps along the marked line on both piers, bend the channel steel into the overflow surface curve, and weld it segment by segment on the cramp heads to form an overflow surface slip form track; first weld the downstream part of the slip form track. When the length of the welded slip form track is greater than the module length, install the formwork on the slip form track, and then continue to weld the remaining slip form track; The template is composed of multiple module units connected in sequence. Each module unit includes a strip-shaped inner module, a connecting piece, and connecting modules arranged on both sides of the inner module; first through holes and second through holes are respectively provided at the upper and lower ends of the inner module, and first connection holes and second connection holes are respectively provided at the upper and lower ends of the connecting module; the first through holes are aligned with the second connection holes on both sides, and the second through holes are aligned with the first connection holes of adjacent module units. Each pair of aligned holes is rotatably connected through an independent connecting piece; Sliders are integrally formed on the outer sides of both the connecting module and the lower-end module and are used for sliding connection with the sliding grooves of the formwork towing track; S3. Pour the concrete in layers; pour the concrete in layers from bottom to top. After the concrete in the current pouring layer starts to set, the traction mechanism pulls the template upward along the formwork towing track to carry out the pouring of the next layer of concrete; after each layer of pouring is completed, vibrate the concrete to ensure its compaction; S4. Trowel and finish the overflow surface after pouring, cover the concrete on the overflow surface with a curing blanket and cure it with running water.

[0006] Furthermore, the width of the module is determined according to the overflow surface curve. The calculation formula for the width of the inner module is:

[0007] where, is the minimum radius of curvature of the reverse arc section of the overflow surface curve, is the allowable error, .

[0008] Furthermore, the template further includes an upper-end module and a lower-end module. A third through hole is provided on the upper-end module, and a third connection hole is provided on the lower-end module; the third through hole is aligned with the first connection hole of the first module unit, and both sides of the second through hole of the last module unit are respectively aligned with the third connection hole. Each pair of aligned holes is rotatably connected through an independent connecting piece.

[0009] Furthermore, the upper and lower ends of the inner formwork, the connecting formwork, the upper-end module, and the lower-end module are all processed into arcs.

[0010] Furthermore, the width of the inner module is equal to twice the width of the upper-end module, and the length of the connecting module is equal to twice the length of the lower-end module.

[0011] Furthermore, the traction mechanism adopts a winch, and the steel wire rope of the winch is connected to the template.

[0012] Furthermore, the connecting module is made of high-strength steel; the connecting piece is a high-strength pin shaft; an anti-adhesion coating is provided on the inner surface of the template.

[0013] Furthermore, the sliding groove adopts a sliding groove with a T-shaped structure, the slider adopts a slider with a T-shaped structure, and the openings of the sliding grooves on both sides are arranged oppositely.

[0014] Further, reinforcing ribs are provided on the outer surface of the formwork.

[0015] Further, temperature adjustment pipelines are arranged inside the formwork for circulating cooling liquid in high-temperature environments and circulating heating media in low-temperature environments.

[0016] The present invention has the following advantages compared with the prior art: By roughening and flushing the reserved surface of the dam, the present invention can effectively remove surface impurities and scum, and increase the bonding force between the new and old concretes; by using a total station to set the line on the side of the pier and accurately marking the overflow surface curve on both sides of the pier, the accuracy of the shape and position of the overflow surface is ensured; when the length of the welded trailing formwork track is greater than the module length, the formwork is installed and the remaining track is continued to be welded; after each layer of concrete is poured, the concrete is vibrated to ensure the density of the concrete; the formwork and the trailing formwork track are connected by a sliding connection through a chute. During the concrete pouring, the formwork can slide smoothly along the trailing formwork track, evenly bear the pressure and finely adjust the balance of the lateral force, effectively avoiding the deformation or explosion of the formwork, and ensuring the stability and safety of the construction; at the same time, the structure of the formwork in this application can adapt to the curvature change of the demoulding track, and the formwork has high versatility.

[0017] Through modular design, the formwork is divided into an upper module, a lower module and a plurality of module units. The module units are rotationally connected through independent connecting pieces, and a slider is integrally formed on the outer side of the connecting module for sliding connection with the chute of the trailing formwork track. This design enables the formwork to be installed by installing the assembled modules into the trailing formwork track during installation. Since the formwork in the present invention can adapt to the curvature change, compared with the traditional segmented formwork that requires different formworks to be installed in different curvature sections, the time for repeated disassembly and assembly is saved, and the installation steps are greatly simplified. At the same time, during the construction process, when the concrete of the current pouring layer begins to set, the traction mechanism can pull the formwork to move upward along the trailing formwork track to carry out the pouring of the next layer of concrete, without repeatedly disassembling and reinstalling the formwork, reducing the time for formwork installation and adjustment, and effectively solving the problem of low construction efficiency.

[0018] The technical solution of the present invention will be further described in detail below with reference to the drawings and embodiments. Description of the Drawings

[0019] Figure 1 It is a schematic cross-sectional structure diagram before the overflow surface pouring in the embodiment of the roller-compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 2 It is a schematic structural diagram after the overflow surface pouring in the embodiment of the roller-compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 3Schematic front view structure diagram of the module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 4 Schematic top view structure diagram of the module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 5 Schematic right view structure diagram of the module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 6 Schematic front view structure diagram of the formwork after the first module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention is connected to the upper module; Figure 7 Schematic front view structure diagram of the formwork after the last module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention is connected to the lower module; Figure 8 Schematic right view structure diagram of the formwork after the last module unit of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention is connected to the lower module; Figure 9 Schematic sectional structure diagram of the demoulding track of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention; Figure 10 Schematic process diagram of the formwork for the embodiment of the roller compacted concrete modular construction and prefabricated assembly method of the present invention; Explanation of reference numerals: 1, Dam reserved surface; 2, Overflow surface curve; 3, Pier; 4, Overflow surface; 5, Overflow hole; 6, Module unit; 7, Upper module; 8, Lower module; 9, Inner module; 10, Connection module; 11, Slide block; 12, Drag formwork track; 13, Chute; 14, First connection hole; 15, Second connection hole; 16, Third connection hole; 17, Second through hole. Detailed implementation manners

[0020] Embodiment of the roller compacted concrete modular construction and prefabricated assembly method: As Figure 1-10 shown, a roller compacted concrete modular construction and prefabricated assembly method includes the following steps: S1, Construction preparation; As Figure 1 - Figure 2As shown in the figure, the main body of the dam is cast with roller-compacted concrete. The reserved surface 1 of the dam below the overflow hole 5 on the main body of the dam is roughened and washed clean. The reserved surface 1 of the dam is roughened and washed clean. The total station is used to set the line on the side of the pier 3, and the overflow surface curve 2 is marked on the two side piers 3. Reinforcement bars are tied on the reserved surface 1 of the dam, and the reinforcement bars of the overflow surface 4 are tied and welded at one time. The roughening treatment shall ensure that the roughness of the bonding surface reaches the standard of the unevenness ≥ 5mm.

[0021] S2. Formwork installation: On the two side piers 3, cramps are driven along the marked line. The channel steel is bent into the overflow surface curve 2 and welded to the cramp heads in sections to form the drag formwork track 12 of the overflow surface 4. First, the downstream part of the drag formwork track 12 is welded. When the length of the welded drag formwork track 12 is greater than the module length, the formwork is installed on the drag formwork track 12, and then the remaining drag formwork track 12 is continuously welded. The cramps are selected with a diameter of 32mm, a length of 100cm, and an inserted length of 80cm; the channel steel is 20# channel steel. The modules are assembled before installation and then installed.

[0022] This module can adapt to the curvature change; specifically, the formwork is composed of multiple module units 6. First, the formwork main body is formed by connecting multiple module units 6. Each module unit 6 includes a strip-shaped inner module 9, a connecting piece, and connecting modules 10 arranged on both sides of the inner module 9.

[0023] The upper and lower ends of the inner module 9 are respectively provided with a first through hole and a second through hole 17, and the upper and lower ends of the connecting module 10 are respectively provided with a first connecting hole 14 and a second connecting hole 15; the first through hole is aligned with the second connecting holes 15 on both sides and is rotationally connected through a connecting piece; the second through hole 17 is aligned with the first connecting hole 14 of the adjacent module unit 6 and is rotationally connected through a connecting piece. Through this structure, the formwork main body can be bent, that is, the function of adapting to the curvature can be realized. In this way, when facing different curvatures of the overflow surface 4, it is not necessary to make multiple bent formworks. When the curvature changes, the formwork on the drag formwork track 12 is replaced.

[0024] In order to make the formwork complete, the formwork also includes an upper end module 7 and a lower end module 8, which are used to be arranged at the front end and the rear end of the formwork main body respectively. Specifically, the upper end module 7 is provided with a third through hole, and the lower end module 8 is provided with a third connecting hole 16; the third through hole is aligned with the first connecting hole 14 of the first module unit 6, and both sides of the second through hole 17 of the last module unit 6 are aligned with the third connecting hole 16, and each aligned hole is rotationally connected through an independent connecting piece. Specifically, the connecting piece is a high-strength pin shaft.

[0025] To achieve the connection between the formwork and the stripping track 12, sliding blocks 11 are integrally formed on the outer sides of both the above-mentioned connection module 10 and the lower-end module 8 for sliding connection with the chute 13 of the stripping track 12. The existing formwork is not directly connected to the stripping track 12 but is indirectly connected through a framework. The formwork is arranged above the overflow surface 4 to be concreted under the action of gravity and pressure, so weights need to be added to press the formwork tightly; in this solution, through the sliding connection method, the situation that the formwork is extruded out of the overflow surface 4 by the poured concrete is avoided. To facilitate processing, the chute 13 is a chute with a T-shaped structure, and the sliding block is a sliding block with a T-shaped structure. The openings of the two side chutes 13 are arranged facing each other; this improves the connection reliability between the stripping track 12 and the formwork. The chute 13 can also be other special-shaped chutes.

[0026] To prevent the formwork from bending adaptively and causing the unevenness of the overflow surface 4. The width of the inner module 9 is determined according to the overflow surface curve 2, and the calculation formula for the width of the inner module 9 is:

[0027] where is the minimum radius of curvature of the reverse arc section of the overflow surface curve 2, is the allowable error, .

[0028] Taking as an example, the width of the inner formwork can be calculated to be 0.56 m. The value range of the width of the inner formwork is 0.5 m to 1.5 m.

[0029] To facilitate the rotation of the internal components of the formwork, the upper and lower ends of the inner formwork, the connecting formwork, the upper-end module 7, and the lower-end module 8 are all processed into arcs. Through this design, the process of replacing formworks with different curvatures during the construction of the overflow surface 4 is avoided, thus saving time.

[0030] To ensure the tightness of the formwork, the width of the inner module 9 is equal to twice the width of the upper-end module 7, and the length of the connection module 10 is equal to twice the length of the lower-end module 8.

[0031] To better drag the formwork, the above-mentioned traction mechanism uses a winch, and the steel wire rope of the winch is connected to the formwork. The above-mentioned connection module 10 is made of high-strength steel.

[0032] To facilitate stripping, an anti-sticking coating is provided on the inner surface of the formwork. The anti-sticking coating uses butter, and the butter can be applied before construction.

[0033] To increase the strength of the formwork, reinforcing ribs are provided on the outer surface of the formwork.

[0034] S3. Pour the concrete in layers; pour it layer by layer from bottom to top. After the concrete in the current pouring layer starts to set, the traction mechanism pulls the formwork upward along the formwork track to pour the next layer of concrete. After each layer is poured, vibrate the concrete to ensure its compaction. When pouring in layers, the thickness of each pouring layer is 0.5 m. The poured concrete has a grade of C35W8F100, and the concrete is impact-resistant and wear-resistant concrete with steel fibers added.

[0035] During the process of pouring the concrete in layers, the secondary vibration technology is adopted. That is, before the concrete starts to set, vibrate the already poured concrete again to make the concrete more compact, eliminate the air bubbles and cavities inside the concrete, and improve the strength and impermeability of the concrete.

[0036] S4. Trowel and finish the overflow surface 4 after pouring, and cover the concrete of the overflow surface 4 with a curing blanket and cure it with running water.

[0037] In order to improve the performance of the poured overflow surface 4, temperature adjustment pipes are arranged inside the formwork, which are used to circulate the cooling liquid in high-temperature environments and circulate the heating medium in low-temperature environments. That is, in high temperatures, by circulating the cooling liquid, prevent the concrete from cracking due to excessive temperature; in low-temperature environments, introduce the heating medium to maintain the temperature of the formwork, ensure the normal setting and strength growth of the concrete, and improve the construction quality of the concrete.

[0038] The above are only the preferred embodiments of the present invention, and do not impose any limitations on the present invention. Any simple modifications, changes, and equivalent structural changes made to the above embodiments according to the technical essence of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. A method for modular construction and prefabricated assembly of roller-compacted concrete, characterized in that: The steps are as follows: S1. Construction preparation: The main body of the dam is poured with roller-compacted concrete. The reserved surface on the main body of the dam is roughened and washed clean. The total station is used to set the line on the side of the gate pier (3), and the overflow surface curve (2) is marked on both sides of the gate pier (3). Reinforcing bars are tied on the reserved surface (1) of the dam; S2. Formwork installation: Tie rods are driven along the marked lines on both sides of the gate pier (3). The channel steel is bent into the overflow surface curve (2) and welded section by section on the tie rod heads to form the trailing form track (12) of the overflow surface (4). First, weld the trailing form track (12) of the downstream part. When the length of the welded trailing form track (12) is greater than the module length, install the formwork on the trailing form track (12), and then continue to weld the remaining trailing form track (12); The formwork is composed of multiple module units (6) connected in sequence. Each module unit (6) includes a strip-shaped inner module (9), a connecting member, and connecting modules (10) arranged on both sides of the inner module (9). First through holes and second through holes (17) are respectively arranged at the upper and lower ends of the inner module (9). First connection holes (14) and second connection holes (15) are respectively arranged at the upper and lower ends of the connecting module (10). The first through hole is aligned with the second connection holes (15) on both sides, and the second through hole (17) is aligned with the first connection hole (14) of the adjacent module unit (6). Each pair of aligned holes is rotatably connected through an independent connecting member; Sliders (11) are integrally formed on the outer sides of the connecting module (10) and the lower end module (8) for sliding connection with the chute (13) of the trailing form track (12); S3. Pour concrete in layers: Pour in layers from bottom to top. After the concrete of the current pouring layer starts to set, the traction mechanism pulls the formwork upward along the trailing form track to carry out the pouring of the next layer of concrete. After each layer is poured, vibrate the concrete to ensure its density; S4. Finish troweling and polishing the poured overflow surface (4), and cover the concrete of the overflow surface (4) with a curing blanket and cure it with running water.

2. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 1, characterized in that: The width of the inner module (9) is determined according to the overflow surface curve (2). The calculation formula for the width of the inner module (9) is: Among them, is the minimum radius of curvature of the reverse arc section of the overflow surface curve (2), is the allowable error, .

3. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 1, characterized in that: The formwork further includes an upper end module (7) and a lower end module (8). A third through hole is arranged on the upper end module (7), and a third connection hole (16) is arranged on the lower end module (8). The third through hole is aligned with the first connection hole (14) of the first module unit (6), and both sides of the second through hole (17) of the last module unit (6) are respectively aligned with the third connection hole (16). Each pair of aligned holes is rotatably connected through an independent connecting member.

4. A method for roller compacted concrete modular construction and prefabricated assembly according to claim 3, characterized in that: The upper and lower ends of the inner formwork, the connecting formwork, the upper end module (7), and the lower end module (8) are all processed into arcs.

5. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 3, characterized in that: The width of the inner module (9) is equal to twice the width of the upper end module (7), and the length of the connecting module (10) is equal to twice the length of the lower end module (8).

6. A roller-compacted concrete modular construction and prefabricated assembly method according to claim 1, characterized in that: The traction mechanism uses a winch, and the steel wire rope of the winch is connected to the formwork.

7. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 1, characterized in that: The connecting module (10) is made of high-strength steel; the connecting member is a high-strength pin shaft; and an anti-adhesion coating is provided on the inner surface of the formwork.

8. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 1, characterized in that: The chute (13) adopts a chute with a T-shaped structure, the slider adopts a slider with a T-shaped structure, and the openings of the two side chutes (13) are arranged facing each other.

9. A roller compacted concrete modular construction and prefabricated assembly method according to claim 1, characterized in that: Reinforcing ribs are arranged on the outer surface of the template.

10. A method for roller-compacted concrete modular construction and prefabricated assembly according to claim 1, characterized in that: A temperature adjustment pipeline is arranged inside the template, which is used to circulate the coolant in a high-temperature environment and circulate the heating medium in a low-temperature environment.

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